Shell Gasification Process Brosch re_2003.

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A company
of ThyssenKrupp
Technologies

Uhde

tk

The Shell Gasification Process

The Shell Gasification Process

Contents
1.

Company Profile

2.

Introduction

3.

Process Configuration

3.1

Basic Reactions

3.2

Main Technology Steps

3.3

Advantages of the Shell Gasification Process (SGP)

3.4

Reliability Data

4.

Gasification Process Flexibility

4.1

SGP and Integrated Gasification Combined Cycle (IGCC)

4.2

SGP and Chemical Products

5.

Shell Pernis Worlds First Oil Based IGCC / H2 Plant

6.

Uhde and Gasification

7.

Reference List Shell Gasification Process

... / 1
1.

Company Profile

To date the Dortmund-based engineering contractor, with its highly specialised

workforce of around 3,500 and its international network of subsidiaries and
branch offices, has successfully completed over 2,000 projects around the
world.

Uhde's international reputation has been built up on the successful application

of Engineering with ideas to produce cost-effective, high-tech solutions for its
customers. The increasing importance placed upon process and application
technology in the fields of oil & gas, chemicals, fuels, energy and
environmental protection is met by a combination of process development,
specialist know-how, all-around service packages, top-quality engineering and
impeccable punctuality.

Uhde provides more than 250 different processes covering many different
sectors and providing intelligent solutions for the refining, petrochemical and
chemical industries.

Shell Global Solutions International B.V. is owner and licensor of the Shell
Gasification Process (SGP). Uhde is Shells engineering partner for the SGP,
which can be applied for the production of synthesis gas from all liquid and
gaseous feedstocks.

... / 2
2.

Introduction

The growing demand for lighter and cleaner fuel products, the heavier crude oil
sources for the refineries and the economical situation inside the refineries to
downgrade the bottom more and more are changing the configuration of the
refineries.

The introduction of stringent environmental legislation in the United States and in

Europe, coupled with global restrictions on the level of aromatics and sulphur
permitted in automotive fuels, will change the internal hydrogen balance in
refineries. New developments in fuel cell technology will also lead to future market
opportunities for hydrogen. But whilst refineries work to satisfy the increasing
demand for hydrogen worldwide, they are also looking to find the best technological
and most cost-effective way to dispose of their final residues.

Refineries are also searching for a global solution to their emission problems and
are gradually replacing the old furnaces used for the production of power, steam
and heat.

Off-gases, such as those produced in catalytic reformers, have traditionally been

the principal source of hydrogen in refineries. However, the compulsory
reformulation of gasoline has limited the level of aromatic constituents permitted.
This change has reduced catalytic severity leading to an increase in the liquid yield,
but a decrease in the hydrogen yield.

The bulk of hydrogen produced today is generated when light hydrocarbons,

particularly natural gas or LPG, undergo a steam reforming process.

During the refining stages, heavy metals in particular, vanadium, iron and nickel,
which are present in all crude oils are accumulated in the bottom products. In
fact, these residues, which have the highest metal concentration, are the cheapest
feedstocks for gasification units.

... / 3

Nevertheless, gasification is a very versatile process which can be used for

converting even the heaviest bottom of the barrel refinery residues into clean
synthesis gas.

This gas can subsequently be used to produce hydrogen, power, fuel gas or steam
for any refinery purposes, as well as producing gases for the chemical industries
(Fig. 1).

Sour
Water

Sour Water
Treaters

Sulfur Recovery
Plants

Sulfur
Fuel Gas
LPG

Isomerization
Units

Crude

Crude Units

Naphtha
Desulfurizers

Catalytic
Reformers

Distillate
Desulfurizers

Hydrocrackers &
Cat Crackers

Resid &
Heavy Oil
Desulfurizers
Vacuum Units

Tail Gas
Treating Units

Gas Treating
Plants

Alkylation
Units
Gasolines

LPG, Naphtha &

Jet Fuel
Treating Units

Cokers &
Visbreakers
Solvent
Deasphalting

Aromatics
Extraction/
Fractionation

Hydrodealkylation
Units

Kerosene
Jet Fuel
Diesel Fuel
Benzene
Fuel Oil/Coke
Low Sulfur
Fuel Oil
Bitumen

Asphalt Plants
Gasification
Plants

Hydrogen
Recovery

Hydrogen
Syngas

Power Plants

Electric Power

Figure 1: Gasification in the refinery environment

The successful Shell Gasification Process, SGP, is a reliable, efficient and

environmentally benign process. Over the last 40 years more than 160 SGP units
have been built worldwide, many of them for the production of ammonia and
methanol. However, at present the focus is more on power and/or hydrogen
coproduction. An example of the successful implementation of such a project is the
PER+ refinery upgrading project at the Shell Pernis refinery near Rotterdam in the
Netherlands. The Pernis SGP plant has been operating successfully since the end
of 1997.

... / 4
As a technology-oriented company, Uhde can rely on its extensive experience in
the development, design and construction of oil and coal conversion plants. To date
Uhde has designed and built almost 100 gasifiers around the world based on 5
different gasification technologies catering to all types of feedstock solid, liquid
and gaseous. These technologies include upstream and downstream processes
such as heat recovery, gas treatment (including sulphur recovery), waste water
treatment, and subsequent processes for the production of methanol, ammonia,
hydrogen, oxo-chemicals and electrical power.

Uhde has built worlds largest IGCC Power Plant (318 MW

Spain

e, net)

in Puertollano,

... / 5
3.

Process Configuration

The Shell Gasification Process has a long track record of optimum performance
over many years of operation.

The SGP process, initially developed in the 1950s, was primarily used with fuel oil
and bunker C oil as feedstocks. By the 1970s vacuum (short) residue had become
the standard feed. In the 1980s vacuum residues were concentrated even further
by visbreaking and C4/C5 deasphalting. Over time, the feed became heavier and
more viscous, and contained higher levels of sulphur and heavy metals. Shells
continuous developments in this field over the years underpin its dedication to this
particular technology.
3.1

Basic Reactions

Gasification or partial oxidation is a non-catalytic process; a combination of

exothermic and endothermic reactions, thermal cracking, steam reforming etc.

The net reaction

2CHn + O2 2 CO + nH2 (1 < n < 4)
is exothermic and produces a gas which containing mainly CO and H2. The raw
synthesis gas (or syngas) contains small quantities of CO2, H2O and H2S and
impurities, such as CH4, NH3, COS, HCN, N2, Ar and ash, the quantities being
determined by the composition of the feedstock, the oxidant and the actual
gasification temperature (1300 1400 C). A small amount of unconverted carbon
is also present and ranges from 0.5 to 1.0 %wt in liquid feedstocks or 50 200 ppm
wt in gaseous feedstocks.
Hydrocarbon fuels, such as natural gas, refinery gas, bunker C-oil, vacuum residue,
vacuum-flashed cracked residue, asphalt, liquid waste and orimulsion can all be
used as feedstock for the gasification process.

... / 6
Operating pressures ranging from atmospheric pressure to 65 bar can easily be
accommodated but depend upon the desired application of the syngas.

3.2

Main Technology Steps

The Shell Gasification Process consists of three principal stages (Fig. 2):

Gasification (Partial Oxidation), in which the feedstock is converted to syngas

in the presence of oxygen and a moderating agent (steam) in a refractory-lined
gasification reactor;

Syngas Effluent Cooler (SEC), in which high pressure steam is generated

from the hot syngas leaving the reactor;

Carbon Removal, in which residual carbon and ash are removed from the
syngas in a two-stage water scrubbing unit.

PROCESS
STEAM

FEEDSTOCK
SYNGAS

HP STEAM
OXYGEN

FILTRATE
BOILER
FEED WATER

SOOT
SCRUBBER
REACTOR

SYNGAS
EFFLUENT
COOLER

SOOT
QUENCH
SOOT WATER

Fig. 2: The Shell Gasification Process (Gasifier and Syngas Effluent Cooler
manufactured by Standard Fasel Lentjes B.V., The Netherlands)
The final stage involves a soot water processing section, Naphtha Soot Recycling
Unit (NSRU) or Soot Ash Removal Unit (SARU), which recovers carbon from the

... / 7
wash water and separates the metal ash from the carbon to yield a valuable
product.

Both the feedstock and the gasification agent, oxygen, are preheated prior to being
fed to the burner which is a proprietary co-annular burner specially designed for
viscous feedstocks.

The reactors optimal design allows for complete gasification reactions. The burner
is controlled by a managing system which includes a safeguarding system and a
sequence logic block to enable fully automated start and stops and normal
operation during all plant operating conditions.
The recovery of sensible heat from the syngas is an integral feature of the SGP
process. Primary heat recovery takes place in the Syngas Effluent Cooler (SEC)
where high-pressure saturated steam is generated. Secondary heat recovery
occurs in a boiler feed water economiser immediately downstream of the SEC.

The SGP process suspends the carbon (soot) produced by the partial oxidation of
hydrocarbons in the gasifier, in a carbon slurry, which is an aqueous suspension
containing up to 20 g/l of soot and ash. The soot particles and the ash are removed
from the gas in the two-stage water scrubber, comprising:

a quench pipe and soot separator and

a soot scrubber.

About 95% of the soot is removed by a direct water spray in the quench pipe.

The gas then enters the scrubber where it is scrubbed in counter-current flow in a
packed bed using condensate return water and the filtrate from the soot water
processing section.

After leaving the scrubber the syngas has a residual soot

content of less than 4 mg/Nm.

The heavy metals and alkaline-earth metals entering the reactor are transformed
into oxides, sulphides and carbonates, and because these compounds are only
slightly soluble the ash follows the soot water process flow.

... / 8

The SGP process has been used successfully with two different technologies for
separating soot from soot water; the most recent ones is shown in Fig. 3.

Naphtha Soot Recovery Unit

Soot Ash Removal Unit

O2

Soot Water
Oil/Carbon
Oil Part Stream

Carbon/
Naphtha
Extraction

O2
Oil/Heavy Residue
Steam

Gasification
+ Scrubbing

Raw Gas

Soot Water

Water Recycle

Steam

Raw Gas

Water Recycle

Gasification
+ Scrubbing

Oil/ HeavyResidue

Soot Water
Filtration

Waste Water
(Soot + Heavy Metals)

Filter Cake

Waste
Water
Treatment

Filter cake
Burn-off

Heavy Metal Sludge

Heavy Metal Ash

Fig. 3: Naphtha Soot Recovery Unit vs. Soot Ash Removal Unit

In the Naphtha Soot Recovery Unit, NSRU, the soot water is mixed with liquid
hydrocarbons (naphtha) in a proprietary extractor. The hydrocarbons force the soot
particles to agglomerate and to rise and these agglomerates are then sieved-off in
a special rotating sieve. The purified water is recycled back to the scrubbing
section. The naphtha is recovered and the soot becomes a pumpable suspension
in the fresh feedstock (soot oil) which can be recycled and used as feedstock for
the reactor.
The final stage of the NSRU comprises a Waste Water Treatment Unit in which the
heavy metal compounds and the remaining soot are extracted from a small bleed
stream leaving the NSRU.
The latest SGP development in this field is the Soot Ash Removal Unit. This unit
consists of a Soot Water Filtration section and a section for filter cake incineration.
The soot water coming from the scrubber is depressurised and routed to a filter

... / 9
press. Filter cakes with a solid content of approx. 17 20 %wt can be attained. The
filter cake is dried in a special incineration section and the remaining carbon is
burnt off. The final product is a highly valuable heavy metal ash, which is sold to the
metal reclaimer market.

3.3

Advantages of the Shell Gasification Process

The SGP process is a proven technology which is being utilised in a variety of

commercial applications around the world. The benefits to our customers can be
summarised as:

maximum reliability

broad fuel flexibility

optimum efficiency

high operational flexibility

broad product flexibility

flexibility with regard to integration into existing and new plants

excellent environmental performance

standardisation based on years of experience.

One criteria is essential in ensuring the profitability of the gasification units:

R E L IAB IL IT Y .
SGPs optimum process availability and reliability is the result of more than 40
years experience in the design and operation of gasification units and a dedication
to continuous technological developments.
Key developments in the SGP process have resulted in high on-stream factors
which are now routine in a variety of services.
The optimised SGP

reactor design allows

relatively

moderate

process

temperatures (1300 1350 C). The relatively low gasification temperature is

accompanied by minimal heavy metal eutectic formation. There is also very little

... / 10
soot formation and consequently there are fewer deposits on the refractory of the
reactor and less fouling in the SEC. Another result of the moderate gasification
temperature is the comparably low oxygen consumption. Furthermore, the superior
efficiency of the SGP process results in a high CO content and a low CO2 content.
The development of a new generation of burners the co-annular burner has
paved the way for the gasification of highly viscous feedstocks. The inspection of
the burner at high temperatures, a special safeguarding and control system and the
integrated heat-up auxiliary burner have resulted in both very long operating
periods (over 9000 hours) and easy maintenance. The special design allows parts
which are subject to wear and tear to be repaired on site. The normal turn-down
ratio of the burner is lower than 70%; lower is possible with special design. For the
initial phase of the reactor heat-up an auxiliary burner is used. This burner is
integrated with main burner, its insertion and removal is quick and simple.
One of the key elements of the SGP process is the Syngas Effluent Cooler (SEC)
which produces high-pressure steam (Fig. 4).

... / 11

REACTOR

SYNGAS
EFFLUENT
COOLER

Fig. 4.:
SGP Reactor with
Syngas Effluent Cooler
(manufatured by Standard
Fasel Lentjes B.V., The
Netherlands)

The SEC equipment operates with low fouling and high feedstock flexibility. In fact,
intensive investigations were carried out to ascertain the current availabilities of the
cooler, e.g. the special design of the inlet section of the cooler. Efficiency for
electric power generation increases by approx. 5 percentage points, if an SEC is
used instead of a gasifier operated with a direct water quench. The entire design of
the cooler is extremely cost effective, e. g. there is no additional steam drum. The
use of low-alloy steels combined with special design makes the investment costs
for the SEC very low and the return on investment therefore extremely good. As a
consequence, the SEC usually pays for itself within two years. Low maintenance
costs are achieved since the standard maintenance and cleam-outs usually are
required only after two years.
The soot separation/handling system is a deciding factor in the trouble-free
operation of the gasification plant. Over the last few years the development of the
plant configuration has favoured the Soot Ash Removal Unit (SARU). Shell has
developed a proprietary continuous dewatering process for soot and ash. The

... / 12
process uses a filter press and a carbon burn-off process which is completely
reliable and which does not affect the availability of the gasification unit. The Soot
Ash Removal Unit has the following advantages over a Naphtha Soot Recovery
Unit:

The SARU is a typical once-through system with spare capacity in cheap tanks
rather than in expensive filtering systems.

Lower capital requirements and operating costs (automated operation, no use

of naphtha)

Hardly any heavy metals in the waste water

No accumulation of heavy metals in the gasification feed. This prevents heavy

metals from attacking the refractory of the reactor. It also prevents increases in
the viscosity of the feedstock and creates less fouling of the Syngas Effluent
Cooler.

The final product (metal ash) is a valuable product which is sold to metal
reclaimers.

The latest development to the SGP process is the standardised Safeguarding and
Control System. This system includes all the safety measures, which have been

implemented during the development of gasification technology. The special

modular structure means that the commissioning and start-up of the gasification
plant is extremely efficient. The highly automated control system supports the
operator in all aspects of plant operation (start-up, shutdown, stand-by) and avoids
trips of non-safety nature. In fact, this system enables the plant to be started
automatically within 10 minutes and also minimises flaring of the gases produced
during the initial phase of plant operation.
It is even possible to replace the conventional blast burner with a co-annular burner
in existing SGP plants. The Safeguarding and Control System can be easily
adapted to the old plant configuration thanks to its unique modular structure.

... / 13
3.4

SGP and IGCC

Data obtained from SGP units already in operation have provided the following
average figures for availability and replacements over a 10 year operating period:

The overall availability for a typical 4-train SGP is 96 %

Typical shutdown time for 1 train:

Burner inspection/replacement
Replacement of thermocouple in the reactor
Upstream/downstream causes
Non-scheduled shutdown
Total

On-stream factor: 1 train 98 %:

Gasifier and syngas efluent cooler
Soot scubbing

98.4 %
99.6 %

Replacement schedule:
Replacement of burner/internals
Coils of the syngas effluent cooler
Refractory gasifier

every year
5 - 8 years
5 - 8 years

days per year

4
1
1
2
8

Since the SGP IGCC/H2 cogeneration complex started operation in Pernis, further
improvements to its availability and reliability have been observed.

... / 14
4

Gasification Process Flexibility

Many different gaseous and liquid feedstocks are used for the SGP process.
Although the SGP process is standardised (see Table 1 specific raw gas
production data for the SGP process), any applications affecting the final product
are tailored to the customers requirements using an optimum route for treating and
purifying the syngas (Fig. 5).

The following applications are described in more detail

SGP + IGCC

SGP + chemical products, such as ammonia, hydrogen, oxo-gas and

carbon monoxide.

Hydrogen
Chemicals
Feedstock
Clean Syngas for
Refinery Use
Gasification
&
Gastreating

Clean
Syngas
(CO + H2)

Oxygen

Fig. 5: Typical SGP applications

Boilers
Furnaces
(Electricity)
(Steam)

Synthesis of
Hydrocarbons

Liquid
Transportation
Fuels

Integrated
Gasification
Combined Cycle

Electric Power
Steam

... / 15
SGP and IGCC

What is an IGCC plant?

Integrated Gasification Combined Cycle (IGCC) involves the integration of the

gasification island into a combined cycle power plant (fig. 6), comprising
-

the gasification unit, in which the primary fuel is converted into raw gas. The
solid and gaseous impurities are removed in a scrubbing section and in a gas
treatment section;

the Combined Cycle Gas Turbine (CCGT) system, which converts the clean
gas into electricity.

Oil/Heavy Residue
Gasification

Air Separation

Oxygen

Syngas
Effluent Cooler
Soot Water

Air

Water

Soot Scrubbing

Filtrate

Soot Ash
Removal Unit
Blow

H2 S Removal
Humidification

Metal Ash

Down

Waste Water
Treatment

Water

Sour Gas

Air

Gas
Turbine

Sulphur
Recovery

Heat
Recovery

Sulphur

Flue Gas

Steam

Syngas
BFW

4.1

G
Steam Turbine

Condenser

Fig. 6. SGP based IGCC power station

An Air Separation Unit (ASU) is also required for the gasifier operation. As a rule,
the oxygen for the gasification unit is more than 95 % pure which means the
equipment needed for the gas path can be reduced in size.
The nitrogen extracted is used in the gas turbine to reduce the NOx emissions
which are formed by the combustion of the clean syngas in the gas turbine for
power generation. The exhaust heat from the gas turbine is used to produce steam

... / 16
in a heat recovery steam generator, which, together with the steam generated in
the Syngas Effluent Cooler of the gasification section, is routed to a steam turbine
used to generate more power.
This approach has the potential to raise the conversion efficiency above that of the
conventional steam cycle if all elements of the plant are integrated optimally, that is:

integration of extracted air for the Air Separation Unit from the gas turbine air
compressor for reducing internal power consumption

integration of nitrogen as a by-product for reducing the NOx emissions

integration of the heat from the steam produced in the Syngas Effluent Cooler
into the CCGT steam cycle for increasing conversion efficiency

optimum use of low-level heat from both the CCGT and the gas treatment
section for preheating and saturation (moisturing) of the syngas for increasing
conversion efficiency.

This optimum integration of the major elements in the power station results in highlevel efficiency (approx. 45 %, LHV-based). As far as environmental acceptability is
concerned, this type of power station can compete with the most efficient
conventional power stations based on other fuels (e.g. coal-fired power stations).
The power stations ability to supply clean gas for a number of applications
(hydrogen, oxo-gas, carbon monoxide etc.), as well as the low-value feedstock
used (high in sulphur and heavy metals), provides the plants with a much stronger
market potential than cheap natural gas power generation.
The integration of the IGCC into refineries leads to additional synergies for both
plants less emissions and lower investment cost by optimum integration of steam,
power and fuel gas produced by the IGCC.

The following atmospheric emissions recorded for an IGCC with the SGP process
emphasise its environmental advantages:

... / 17

NOx

25 mg/Nm (dry 15 % O2)

SO2

10 mg/Nm (dry 15 % O2)

CO

< 10 mg/Nm (dry 15 % O2)

Particulates

< 1 mg/Nm (dry 15 % O2).

Despite the poor quality feedstocks, the emissions are still extremely low. The
sulphur recovery efficiency, defined as a ratio between the liquid sulphur recovered
and the sulphur in the feedstock, is > 99.5 %.

Typical Data for SGP Feedstocks

Feedstock Type

Natural
Gas

Vacuum
Residue

Liquid
Coke

Liquid
Waste

Feedstock Properties
-

1.10

1.25

0.95

3.35

9.7

11.9

9.2

6.8

8.0

3.1

Specific Gravity , 15C

C/H Ratio, weight
Sulphur , %wt

0.08

0.16

0.01

Feedstock [kg]

330

350

350

360

Oxygen Feed 99.5 %

SGP Product Gas (150C, 62 bar)

365

333

316

390

Hydrogen & Carbon Monoxide

95.3

92.9

92.8

94.0

H2/CO Ratio ( mole/mole )

1.69

0.88

0.78

0.89

890

650

615

740

Ash, %wt

Composition , % vol. ( Dry)

Steam Export [kg]

2)

Basis: Production of 1,000 m 3 (N)

1)

of CO+H 2

1)

m3(N) = m 3 at 0C and 1.013 bar

2)

steam production corrected by gasification steam consumption

Table 1: Typical data of the SGP process for different feedstocks

Table 1 shows the characteristics of feedstocks, from vacuum-flashed cracked

residues to liquid coke, produced by a visbreaker working in the Deep Thermal
Conversion mode (DTC licensed by Shell Global Solutions International B.V.).
In refineries, the SGP is particularly attractive when used in conjunction with power
generation:

... / 18
-

Refineries which are under pressure to invest mainly in SO2 and NOx reduction
may find that the use of clean syngas in furnaces or boilers is a very costeffective way to avoid having to make investments for environmental reasons.

A key factor in solving the global CO2 problem in the future will be linked to true
energy pricing and competition. Improved efficiencies, closed product cycles
and cogeneration are just some of the solutions to this problem. Cogeneration
of Power and Hydrogen should be a must for any refinery wishing to solve
future problems with heavy crude wastes, cleaner automotive fuels and
emission reduction.

Refinery heat is often distributed at the level of MP steam. This heat can be
supplied from the steam turbine process either directly from the heat recovery
steam generator or by extracting heat from the steam turbine.

The SGP can handle any heavy feedstock. Consequently the refineries can
utilise deeper conversion (see DTC) which leaves a residue that can yet be
processed by SGP. It is possible for the refineries to increase their profits by
using heavier sulphur and, consequently, cheaper crude.

4.2

SGP and Chemical Products

The SGP process was first used for the production of syngases used in the
chemical industry (primarily ammonia and methanol). The following examples of
various SGP process applications demonstrate its versatility:
-

SGP for ammonia

The total production capacity of the SGP-based ammonia plants around the
world is over 35 million Nm (H2+CO) per day. Ammonia is one of the most
popular gasification products.
-

SGP for hydrogen

Hydrogen will be in huge demand as a fuel in the future, either in fuel cells or in
the automotive industry. The hydrogen demand in refineries is growing
constantly as attempts are made to comply with global legislation dictating low
sulphur contents.
-

SGP for methanol

... / 19
The advantage of using the SGP for methanol production is that the gas can be
produced at a pressure level suitable for modern low pressure synthesis
processes without requiring further compression. The total production capacity
of SGP-based methanol plants around the world exceeds 10 million Nm
(H2+CO) per day.
-

SGP for CO and Oxo-Gas

The high CO content (approx. 45 %) in raw synthesis gas makes the SGP a
natural choice for the production of oxo-syngas and pure CO. The total
production capacity of SGP based oxo-syngas and CO production plants is over
5 million Nm (H2+CO) per day.
Which gas treatment and purification systems are to be used depends on the purity
requirements and the economics of the particular application.
The SGP process provides an excellent opportunity for turning low-value liquid
residues into high-value products by cogenerating electrical power and gaseous
products. The use of syngas for refinery-based power generation increases the
synergy with other refinery needs. In general, less than 10 % of refinery fuel is
required to cover the hydrogen and energy demand of a typical refinery when using
the SGP process.

... / 20
5.

Shell Pernis Worlds First Oil-Based IGCC / H2 Plant

The Shell Gasification Process used in the Shell Pernis Refinery in the Netherlands
is a fine example of state-of-the-art technology (Fig. 7).

Fig. 7: Worlds first oil-based IGCC / H2 Plant in Pernis, The Netherlands

The Shell Pernis plant is the first IGCC in the world to operate using heavy oil
residue gasification. It produces about 115 MW electric power and 285 t/d of pure
hydrogen.
In a refinery environment, one of the most popular gasification products is hydrogen
which can be used in hydrocracking- or hydrodesulphurisation units. Often,
however, the residues used for gasification and for the refineries hydrogen
requirements produce a surplus of syngas, which can then be used for highefficiency, combined cycle power generation, e.g. for power export over the fence.
In Pernis, the three-train gasification plant has a capacity of 1,650 t/d (approx.
11,000 b/d) and uses a heavy, vacuum-flashed, visbroken residue as feedstock.
About 1,600 t/d oxygen are supplied by a third-party source nearby. The main

... / 21
reason for having three gasification trains is that if one gasifier needs to be taken
off-line, the hydrogen requirement for the hydrocracker can still be provided by the
two remaining trains.
The hydrocracker requires up to approximately 285 t/d hydrogen. In a normal threetrain operation, the syngas, which exceeds the requirements for hydrogen
production, will be used as gas turbine fuel.
The hydrogen plant consists of a two-stage CO shift (high temperature/low
temperature), carbon dioxide removal and a methanation stage. A highly integrated
gas treatment unit (Rectisol) was selected for removing H2S from the syngas and
for removing CO2 downstream of the low-temperature CO shift.
The scrubber water (containing soot and ash) from the three trains is filtered and
returned to the scrubber. Excess water is fed to water treatment facilities and the
filter cake is processed for metal recovery.
The Pernis SGP plant has been in operation since the end of 1997 and has been
extremely successful in using the latest technological developments in the Shell
Gasification Process, which are:
1. The development of the co-annular gasification burner enabling the processing
of more viscous feedstocks.
2. The combination of the specific SGP reactor design with the co-annular burner
permits the operation of the gasification unit with low soot make and relatively
low operating temperatures resulting in a relatively low oxygen demand and CO2
production.
3. The development of an open loop soot/ash removal. This enables the
production of a marketable, concentrated, high-value vanadium/nickel ash and
prevents the problems associated with heavy metal enrichment and increased
feedstock viscosity.

... / 22
6.

Uhde and Gasification

Being a technology-oriented company, Uhde can rely on extensive experience in

the development, design and erection of oil and coal conversion plants. This
experience dates back approximately 65 years and has been improved
continuously up to the present day. Figure 8 illustrates the development of Uhdes
experience in gasification technology development and realised plants:
W i n k le r
192 6

= E,P,C by Uhde
K T- 19 41
D e v e lo p m e n t

= Milestone for reference

K T- 19 51
M a z in g a rb e , F

K T ( o il) - 1 9 5 2
Tex aco - 19 53

S h e ll - 1 9 5 3

T G P L ic e n s e

S G P ( O il)

O u lu , F in la n d

K T- 1 956
T o ky o , J a p a n

K T- 19 57
P u e n t e s , S p a in

K T ( o il) - 1 9 5 7
Z a n d v o o rd e , B

Tex aco - 19 59

K T ( o il) - 1 9 5 8

L a s P a lm a s , S p a in

E s ta rre ja , P o rt .

Tex aco - 19 60

S G P - 1 96 4

L is b o n , P o rt u g a l

K U s f irs t S G P

K T - 19 62
P t o le m a is , G r.

K T (g a s ) - 1 9 6 5
T a lk h a , E g y p t

K T - 19 65
M a e M o h , T h a il.

K T ( o il) - 1 9 6 8
Z e it z , G e rm a n y

K T - 19 68

L a v e r a , F ra n c e

Tex aco - 19 71
R h o d e s , A u s t r a lia

TC G P - 1 973
D e v e lo p m e n t

TC G P - 1 978
D e m o H o lt e n , D

TC G P - 1 986
O b e rh a u s e n , D

168 SGP Reactors (Shell reference)

Tex aco - 19 71

K ta h ya , T u r ke y

H TW - 1 973
S h e ll -K o p p e r s - 1 9 7 4

K T - 19 75

S t a rt o f D e v e lo p m e n t

M o d d e r f o n t e in

D e v e lo p m e n t

K T - 19 76
Z a m b ia

K T - 19 78

H TW - 1 978

T a lc h e r, In d ia

F re c h e n

S h e ll -K o p p e r s - 1 9 8 0

K T - 19 78

D e m o H a m b u rg , D

R am ag unda m , I.

K T - 19 84
K ta h ya , T u r ke y
S C G P -1 9 8 5
H ous ton, U S A

H TW - 1 985
B e rre n ra th

P RE NFLO -198 6
F r ste n h a u s e n , D

K T - 19 86
Z e it z , G e rm a n y

K T - 19 88
I n d e c o , Z a m b ia

H TW - 1 988
O u lu , F in la n d

H TW - 1 989
W e s s e lin g

Tex aco - 19 91
O b e r h a u se n , D

S C G P -1 9 9 4
B ugg enum , NL

K o B ra ( n o t re a l. )
P RE NFLO -199 7
P u e rt o lla n o , S p a in

S G P - 1 997
Tex aco - 19 98

H TW - 1 993

P e rn is , N L

B h a r u c h , I n d ia

S G P - 1 998
S G P C o o p e ra tio n
S h e ll / K U

S C G P - 19 99
R e - u n if ie d C o o p e r a t io n
S h e ll / K U

H TW - 2 000
S H I, J apa n

H TW - 2 002
V re s o v a , C z .

Fig. 8: Development of Uhdes Gasification Portfolio

... / 23
As shown in Fig. 8, Uhde has designed and built about 100 gasifiers worldwide
based on 5 different gasification technologies (Shell, PRENFLO, Koppers-Totzek,
High-Temperature Winkler, Texaco) catering to almost all feedstocks - solid, liquid
and gaseous. These technologies include upstream and downstream processes,
such as heat recovery, gas treatment, waste water treatment, and subsequent
processes for the production of methanol, ammonia, hydrogen, oxo-chemicals and
electrical power.
Shell Global Solutions International B.V.

Shells expertise in refinery processes is unbeaten and the company can provide
in-depth assistance throughout the project cycle, from the design studies to aftersales service.
Synergies: Uhde and the Shell Gasification Process

Both Shell Global Solutions International B.V. and Uhde are world leaders in the
development, design, construction and commissioning of their gasification
technologies. Both companies have been involved not only in the technology
development and front-end basic design of the plants, but also in the detailed
engineering, commissioning, start-up and operation of gasification facilities for
decades.
This unique set-up ensures that the feedback essential for further process
improvements and developments is readily available. This is further supported by
extensive research and development work on all components in the gasification,
gas treatment, refinery and chemical plants.

Uhdes Affiliated Services

Uhde is dedicated to providing its customers with a wide range of services and to
supporting them in their efforts to succeed in business.
With our worldwide network of subsidiaries, affiliated companies, experienced local
representatives and first-class backing from our headoffice, Uhde has the ideal
qualifications to achieve this goal.

... / 24
Uhde places particular importance in interacting with the customers at an early
stage to combine their ambition with our experience. We always aim to give
potential customers the opportunity to visit operating plants and to personally
evaluate such matters as process operability; maintenance and on-stream time. We
aim to build our future business on the confidence our customers place in us.
Uhde provides the entire spectrum of services associated with a technologyoriented engineering contractor. These range from the initial feasibility study, to
financing and project management right up to the commissioning of units and
grass-root plants.
Our broad portfolio of services includes:

feasibility studies / technology selection,

project management,

arranging financing schemes,

financial guidance based on extensive knowledge of local laws, regulations and

tax procedures,

environmental studies,

basic / detail engineering,

utilities / offsites / infrastructure,

procurement / inspection / transportation services,

civil works and erection,

commissioning,

training of operating personnel,

plant operation / plant maintenance

R&D

The policy of the Uhde group and its subsidiaries is to ensure utmost quality in the
implementation of our projects. Our head office and subsidiaries worldwide work to
the same quality standard, certified DIN / ISO 9001 / EN29001.
We remain in contact with our customers even after project completion. Partnering
is our byword. We promote active communication between customers, licensors,
partners, operators and our specialists by organising and supporting technical

... / 25
symposia. This enables our customers to benefit from the development of new
technologies and the exchange of troubleshooting information.

February 1998: Symposium in Chennai, India The Shell Gasification Process

We like to cultivate our business relationships and learn more about the future
goals of our customers. Our after-sales service includes regular consultancy visits
which keep the owner informed about latest developments or revamping
possibilities.
For more information contact one of the Uhde offices near you or see Internet:
www.thyssenkrupp.com/uhde

... / 26
7.

Reference List Shell Gasification Process

The following list summarises all plants applying the Shell Gasification Process currently in
operation. The total amount of SGP gasifiers licensed amounts to over 160.

Licenced Shell
Location
Gasification Process in
operation at Companies

Feedstock

Product

Total
H2+CO
Nm/day

Number
of
reactors

Started

Mitsubishi
Petrochemicals

Yokkaichi, Japan

bunker C oil

syngas

400,000

1961

Kemira Chemicals Oy

Oulu, Finland

bunker C oil

specialities

300,000

1965

DEA Mineraloel AG

Wesseling, Germany

cracked
residue

methanol

1,300,000

1969

Lucky Goldstar
Chemical Ltd.

Naju, S. Korea

bunker C oil

ammonia

500,000

1969

Falconbridge

Santo Domingo, Dom.

Rep.

bunker C oil

reducing
gas

1,440,000

12

1971

Chemopetrol a.s.

Litvinov, Czech Republic vacuum

residue

methanol,
ammonia

3,600,000

1971

Ruhr Oel GmbH

Gelsenkirchen,
Germany

vacuum
residue

ammonia +
methanol

4,300,000

1973

Hoechst Celanese Ltd.

Houston, USA

natural gas

oxo

2,100,000

1977

Fertiliser Corp. of India

Ltd.

Sindri, New Delhi, India

heavy fuel oil

ammonia

2,100,000

1977

National Fertiliser Ltd.

Nangai, New Delhi,

India

bunker C oil

ammonia

2,100,000

1978

Hindustan Fertiliser
Corp. Ltd.

Haldia, New Delhi, India

bunker C oil

ammonia +
methanol

2,100,000

1978

Hydro Agri

Brunsbttel, Germany

vacuum
residue

ammonia

4,500,000

1978

Exxon Chemical
Company

Baton Rouge, USA

heavy fuel oil

oxo

570,000

1978

National Fertiliser Ltd.

Bathinda, India

bunker C oil

ammonia

2,100,000

1978

Ultrafertil S.A.

Araucria, Brasil

asphalt
residue

ammonia

3,300,000

1979

National Fertiliser Ltd.

Bathinda, India

bunker C oil

ammonia

2,100,000

1979

Neyvell Lignite Corp.

Ltd.

Neyvell, Tamil Nadu,

India

bunker C oil

syngas

800,000

1979

Quimigal Adubos

Lavradio, Portugal

vacuum
residue

ammonia

2,400,000

1984

... / 27
Licenced Shell
Location
Gasification Process in
operation at Companies

Feedstock

Product

Number
of
reactors

Started

7,200,000

1985

715,000

1987

60,000

1991

Total
H2+CO
Nm/day

Leuna Methanolanlage
(MIDER)

Leuna, Germany

heavy residue

methanol

Qilu Petrochemical Ind.

Zibu, Shandong, China

vacuum
residue

methanol +
oxo

Fushun Detergent
Chemical Plant

Fushun, Liaoning, China vacuum

residue

oxo

Shell MDS (Malaysia)

Bintulu, Malaysia

natural gas

middle
distilates

7,552,000

1993

JiuJiang Petr. Chem.

Fertil. Comp.

JiuJiang City, Jiangxi,

China

vacuum
residue

ammonia

2,100,000

1996

Inner Mongolia Chem.

Fertiliser Plant

Hohot, Inner Mongolia,

China

vacuum
residue

ammonia

2,100,000

1996

Lucky Goldstar
Chemical Ltd

Yochon-City, S. Korea

bunker C oil

oxo

384,000

1996

Shell Nederland
Raffinaderij B.V.

Pernis, Netherlands

heavy residue

H2 + el.
power

4,662,200

1997

Lanzhou Chem. Industry

Co.

Lanzhou, Gansu, China

vacuum
residue

ammonia

2,100,000

1997

Further SGP licenses have been granted since 1997. These have not yet been added
to the reference list. These plants are in various phases of realisation.

Uhde GmbH
Friedrich-Uhde-Strasse 15
D-44141 Dortmund
Tel.: +49 2 31 5 47-0
Fax: +49 2 31 5473032
www.thyssenkrupp.com/uhde
A company of
ThyssenKrupp Technologies

Design and construction

of chemical and
other industrial plants
Fields of activity:
Refineries
Gas generation
Gas treatment
Synthesis processes
Ammonia, methanol, hydrogen
Fertilisers
Plastics and synthetic fibres
Organic chemicals
Aromatics
Electrochemicals
Bleaching chemicals (H2O2,CIO2 )
Oil and coal gasification
Energy technology
Pharmaceuticals
Infrastructures
General Contracting
Services